New binder composition

ABSTRACT

The invention relates to a new binder composition which is particularly suitable for the manufacture of composite materials utilizing such new binder composition in the required nonwoven materials. Composite materials using such new binder composition in their nonwoven part are suitable, in particular, for composites materials for interior construction, for linings, floor coverings, and for the manufacture of furniture and similar products.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of pending U.S. application Ser. No.13/496,271, filed Apr. 6, 2012, which is the National Stage ofInternational Application No. PCT/US2010/050166, filed Sep. 24, 2010,which claims the benefit of U.S. Provisional Application No. 61/249,916,filed Oct. 8, 2009.

BACKGROUND

The invention relates to a new binder composition which is particularlysuitable for the manufacture of composite materials utilizing such newbinder composition in the required nonwoven materials. Compositematerials using such new binder composition in their nonwoven part aresuitable, in particular, for composites materials for interiorconstruction, for linings, floor coverings, and for the manufacture offurniture and similar products.

Composite materials are increasingly replacing traditional buildingmaterials as construction materials and must be adapted for manifoldapplications. Thus, on the one hand a sufficient mechanical stability isrequired and on the other hand a good workability and low weight arenecessary. There has therefore been no lack of attempts to improveexisting composite materials.

In particular, the combining of wood materials, which are manufacturedfrom comminuted wood and the use of binders, with further materials iswidely used and already known. To this end, the two materials areusually laminated and form a composite material. The selection andcombination of the materials can improve the mechanical properties andat the same time a reduction, e.g. of the weight, can be achieved.

Composite materials based on wooden materials and non-woven fabricsstrengthened by a so called “B-stage” binder are known fromWO2006/031522. The base non-woven fabrics are known, e.g., from U.S.Pat. No. 5,837,620, U.S. Pat. No. 303,207 and U.S. Pat. No. 6,331,339.In WO2008/101678 and WO2008/101679 the state of the art technologiesrelating to wooden laminates comprising reinforcing nonwoven and theirmanufacturing processes are disclosed.

Even though the known technologies, including the aforementionedliterature, provide already very good results in product performance andefficient manufacturing there is still a need for improvements. One ofthe main deficiencies in respect to existing reinforced wooden laminatesis the still limited mechanical strength and stability of theseproducts. In addition, the reinforcing nonwovens exhibit a ratherrestricting brittleness creating handling problems and dust during themanufacturing process and the subsequent lamination steps. For someapplications a more flexible nonwoven product is desired.

It has now been found, that by using a specific binder composition forthe reinforcing nonwoven components of such composite materials theaforementioned problems can be solved and more flexible and less brittlereinforcing nonwovens reduce the handling problems and dust formationduring the manufacturing process and the subsequent lamination steps.

SUMMARY OF THE INVENTION

The present invention relates to a new binder composition comprising (i)at least one B-stage binder and (ii) at least one emulsion, preferably athermoplastic emulsion, in particular the emulsion being based onpolyolefin and/or polyurethane. Preferably, the emulsion is added to theB-stage binder before the binder composition is applied to a textilefabric. The binder composition according to the present invention can beprocessed under B-stage conditions.

The invention further relates to textile structures which comprise thenew binder composition. Such textile structures while being in theB-stage conditions exhibit increased flexibility and improved handlingcapabilities which is advantageous for the processing, e.g. intolaminates. The textile structure is preferably a nonwoven material, awoven fabric or a paper.

The invention further relates to multilayer laminates comprising atextile structure that comprises the new binder composition. Theselaminates exhibit increased flexibility, improved impact resistance andoffer additional advantages during processing. Such composite materialsare particularly suitable for interior construction, for linings, floorcoverings, and for the manufacture of furniture or similar products.

DETAILED DESCRIPTION OF THE INVENTION

Subject matter of the present invention is a new binder compositioncomprising (i) at least one B-stage binder and (ii) at least oneemulsion, preferably a thermoplastic emulsion, in particular theemulsion is being based on polyolefin and/or polyurethane.

The above binder composition is applied to textile structures which thencan be used as semi-finished products for the production of laminates.The binder composition can also be applied during the manufacturing ofthe textile structure.

The semi-finished products comprising the binder composition and thelaminates made thereof are particularly suitable for wooden compositematerials.

Binder

The new binder composition contains at least one so called B-stagebinder composition. The binder composition comprises such B-stage resintogether with at least one emulsion, preferably a thermoplasticemulsion, in particular based upon a polyolefin emulsion, or apolyurethane based emulsion. The binder composition of the presentinvention can be applied to textile structures which can be used for themanufacturing of composite materials and laminates. The bindercomposition can be applied during or after the forming of the textilestructure. The binder composition is applied to the textile structureand then partly cured to B-stage condition. The textile structurecomprising the binder in B-stage condition can then be processed intocomposites or laminates.

B-stage binders within the meaning of this invention denotes bindersthat are only partially cured or hardened and can still experience afinal hardening, e.g., by thermal post-treatment. Such B-stage bindersare exhaustively described in U.S. Pat. No. 5,837,620, U.S. Pat. No.6,303,207 and U.S. Pat. No. 6,331,339. The B-stage binders disclosedtherein are also subject matter of the present description. B-stagebinders are preferably binders based on furfuryl alcohol formaldehyde,phenol formaldehyde, melamine formaldehyde, urea formaldehyde and theirmixtures. Preferably, aqueous systems are concerned. Further preferredbinder systems are formaldehyde-free binders. B-stage binders aredistinguished in that they can be subjected to a multistage hardening,that is, they still have a sufficient binding action after the firsthardening or after the first hardenings so that they can be used for thefurther processing. Such binders are usually hardened after the additionof a catalyst at temperatures of ca. 177° C. (350° F.) in one step.

Preferred B-stage binders are binders based on melamine formaldehyde.Preferably, aqueous systems are concerned. B-stage binders aredistinguished in that they can be subjected to a multistage hardening,that is, they still have a sufficient binding action after the firsthardening or after the first hardenings so that they can be used for thefurther processing.

In order to form the B-stage condition, such binders are optionallyhardened after the addition of a catalyst. The amount of hardeningcatalyst is up to 10% by weight, preferably 0.25 to 7% by weight(relative to the total binder content). For example, ammonium nitrate aswell as organic aromatic acids, e.g., maleic acid and p-toluene sulfonicacid are suitable as hardening catalysts since they allow the B-stagestate to be more rapidly reached. In addition to ammonium nitrate,maleic acid and p-toluene sulfonic acid, all materials are suitable ashardening catalysts that have a comparable acidic function. In order toreach the B-stage the textile structure impregnated with the binder isdried under the influence of temperature without producing a completehardening. The necessary process parameters are dependent on the bindersystem selected.

The lower as well as the upper temperature limit can be influenced bythe selection of the duration and/or by adding or avoiding rather largeor rather strong acidic hardening catalysts and/or by optionally usingstabilizers.

Preferably, the new inventive binder composition consists essentially ofB-stage binder, as described above, and at least one emulsion,preferably a thermoplastic emulsion, in particular the emulsion is beingbased on polyolefin and/or polyurethane. The thermoplastic emulsion ischemically different from the B-stage binder. Thermoplastic emulsionsare not 3-dimensional crosslinking such as a thermoset and therefore cannot be B-staged.

Most preferred the new inventive binder composition consists of oneB-stage binder, as described above, and one thermoplastic emulsion,preferably a polyolefin emulsion or a polyurethane based emulsion.

The aforementioned emulsion is added to the preferably aqueous B-stagebinder before the application of the binder onto the textile structure.Preferably the emulsion is a thermoplastic emulsion. Preferably theemulsion is a polypropylene emulsion or a polyurethane based emulsion.

The inventive binder composition contains, beside the B-stage binder, atleast 0.1% emulsion, based on the total solid content of the bindercomposition, up to a value of approximately 35%. The preferred range isbetween 1% and 10%, the optimum value depending on the binder used.

In general, most of the preferred emulsions are commercially available.Examples are the DSM products NEOXIL Nx777, NEOXIL Nx2728N(polypropylene emulsion) or NEOXIL Nx 6158, NEOXIL Nx5521 (polyurethaneemulsion) as well as the Addcomp products Priex 701, Priex 702 or Priex703 (polypropylene emulsion). Other examples are PVC emulsions orstyrene-acrylic emulsions from Lubrizol or PE emulsions from Michelman.Usually such emulsions comprise additional components such as additives,emulsifiers, stabilizers, etc.

As discussed later the addition of emulsion, in particular for emulsionbased on polyolefin and/or polyurethane, to the B-stage binder inducessurprising effects. Besides a higher flexibility of the textilestructure and less brittleness and dust, laminates made with thesetextile structures exhibit a strongly improved impact resistance whenpolyolefin emulsions were used as second component. When usingpolyurethane emulsions similar effects can be observed regarding dustand brittleness.

Textile Structure (Semi-Finished Textile Product)

The invention further relates to semi-finished textile structures whichcomprise the new binder composition comprising (i) at least one B-stagebinder and (ii) at least one emulsion, preferably a thermoplasticemulsion, in particular the emulsion is being based on polyolefin and/orpolyurethane, said binder composition is at least partially cured andbeing in the B-stage state.

Textile structures according to this invention are all textile fabricsmanufactured from fibers and from which a textile fabric was produced bymeans of a surface-forming technology. The inventive binder compositionis applied to the textile structure during or after the manufacturing ofthe textile structure but prior to any subsequent process steps.

Textile Structures

The textile structures to be provided with the new binder compositionaccording to the present invention can basically be used withoutpre-strengthening binders, in particular chemical binders. However, inorder to ensure the required strengths in the further working of thetextile structures other additional binders can also be introducedand/or known consolidation/mechanical strengthening methods, such asneedling, can be used. In addition to the possibility of a mechanicalstrengthening, e.g., by calendaring or needling, in particular thehydrodynamic needling is also mentioned here. Chemical and/orthermoplastic binders are suitable as binders, as long they arecompatible to the new binder composition according to the presentinvention.

However, the textile structures to be provided with the new bindercomposition according to the present invention are preferablypre-strengthened with a chemical binder. The binders used can be thesame or different but must be selected from the group of the bindersystems compatible with the B-stage binder system according to thepresent invention. The additional binder component is maximally 40% byweight, preferably 30% by weight or less, based on the total weight ofthe textile structure without the B-stage binder composition.

The new binder composition according to the present invention can beapplied to the textile structure after the textile structure has beenformed. When using this so-called off-line process route the additional(pre-strengthening) binder component is preferably 10-30% by weight ofthe total weight of the textile structure. The B-stage bindercomposition is 25-85% by weight, preferably 50-80% by weight based onthe total weight of the final pre-strengthened textile structure butwithout any additives. Final in this context means fiber weight plus anypre-strengthened binder plus B-Stage binder, including solids ofemulsion after curing (=without moisture content) minusfillers/additives in the B-Stage binder, if any.

The new binder composition according to the present invention can alsobe applied during the manufacturing of the textile structure. In thisso-called in-line process the additional (pre-strengthening) bindercomponent can be zero and can be substituted completely by the B-stagebinder composition. The B-stage binder content is 10% to 80%, preferable15% to 75%, most preferable 15% to 50% of the total weight of thetextile structure without any additives or fillers. Such content beingonly the B-Stage binder and solids from the emulsion but no additives orfillers, if any.

The fiber-forming materials for the textile structures are preferablynatural fibers and/or fibers of synthesized or natural polymers, ceramicfibers, mineral fibers or glass fibers that can also be used in the formof mixtures. Textile structures are considered to be tissues, layings,multiaxial fabrics, knitted fabrics, knitwear, woven and non-wovenfabrics, preferably woven and non-woven fabrics. Papers, Kraft papers,balance papers, overlay papers, and decor papers are considered textilestructures as well.

Mineral- and Ceramic Fibers

The textile structures of mineral- and ceramic fibers arealuminosilicate fibers, ceramic fibers, dolomite fibers, wollastonitefibers or fibers of vulcanites, preferably basalt fibers, diabase fibersand/or melaphyr fibers, especially basalt fibers. Daibases and melaphyrsare designated combined as paleobasalts and diabase is also oftendesignated as greenstone.

The mineral fiber non-woven fabric can be formed from filaments, thatis, infinitely long fibers or of staple fibers. The average length ofthe staple fibers in the non-woven fabric of mineral fibers used inaccordance with the invention is between 5 and 120 mm, preferably 10 to90 mm. In a further embodiment of the invention the mineral fibernon-woven fabric contains a mixture of endless fibers and staple fibers.The average fiber diameter of the mineral fibers is between 5 and 30 μm,preferably between 8 and 24 μm, especially preferably between 8 and 15μm.

The weight per unit area of the textile structure of mineral fibers isbetween 15 and 500 g/m², preferably 40 and 250 g/m², wherein these datarefer to a textile structure without any binders, additives or coatings.

Glass Fibers

In the case of the textile fibers of glass fibers non-woven fabrics areparticularly preferred. They are constructed from filaments, that is,infinitely long fibers or of staple fibers. The average length of thestaple fibers is between 5 and 120 mm, preferably 10 to 90 mm. In afurther embodiment of the invention the glass fiber non-woven fabriccontains a mixture of endless fibers and staple fibers.

The average diameter of the glass fibers is between 5 and 30 μm,preferably between 8 and 24 μm, especially preferably between 10 and 21μm.

In addition to the previously cited diameters so-called glassmicrofibers can also be used. The preferred average diameter of theglass microfibers is between 0.1 and 5 μm. The microfibers forming thetextile surface can also be present in mixtures with other fibers,preferably glass fibers. Moreover, a layer-shaped construction ofmicrofibers and glass fibers is also possible.

The textile structure can also additionally have a reinforcement offibers, threads or filaments. Reinforcement threads are preferablymulti-filaments or rovings based on glass, polyester, carbon or metal.The reinforcement threads can be used as such or also in the form of atextile surface structure, e.g., as fabric, laying, knitted fabric,knitwear or non-woven fabric. The reinforcements preferably consist of aparallel thread sheet or of a laying.

The weight per unit area of the textile structure of glass fibers isbetween 15 and 500 g/m², preferably 40 and 250 g/m², wherein the datarefers to a surface structure without any binders, additives orcoatings.

Suitable glass fibers comprise—among others—those manufactured fromA-glass, C-glass, E-glass, S-glass, T-glass or R-glass.

The textile structure can be manufactured according to any known method.For glass non-woven fabrics this is preferably the dry- or wet layingmethod.

Polymer Fibers

Among the textile structures of fibers of synthetic polymers, non-wovenfabrics, especially so-called spun bonds, that is, spunbonded non-wovenfabrics produced by a tangled deposit of melt-spun filaments arepreferred. They consist of endless synthetic fibers of melt-spinnablepolymer materials. Suitable polymer materials are, e.g., polyamides suchas, e.g., polyhexamethylene diadipamide, polycaprolactam, aromatic orpartially aromatic polyamides (“aramids”), aliphatic polyamides such as,e.g., nylon, partially aromatic or fully aromatic polyesters,polyphenylene sulfide (PPS), polymers with ether- and keto groups suchas, e.g., polyetherketones (PEK) and polyetheretherketone (PEEK),polyolefins such as, e.g., polyethylene or polypropylene, cellulose orpolybenzimidazoles. In addition to the previously cited syntheticpolymers, those polymers are also suited that are spun from solution.

The spunbonded non-woven fabrics preferably consist of melt-spinnablepolyesters. In principle, all known types of polyester material suitablefor the manufacture of fibers are considered as polyester material.Polyesters containing at least 95 mole polyethyleneterephthalate (PET),especially those of unmodified PET, are especially preferable.

If the composite materials in accordance with the invention shouldadditionally have a flame-retardant action, it is advantageous if theywere spun from polyesters modified in a flame-retardant manner. Suchpolyesters modified in a flame-retardant manner are known.

The individual titers of the polyester filaments in the spunbondednon-woven fabric are between 1 and 16 dtex, preferably 2 to 10 dtex.

In a further embodiment of the invention the spunbonded non-woven fabriccan also be a bonded fiber fabric hardened by melt binder and whichcontains carrier fibers and melded fibers. The carrier fibers and meldedfibers can be derived from any thermoplastic, fiber-forming polymers.Such spunbonded non-woven fabrics hardened by melt binder are described,e.g., in EP-A-0,446,822 and EP-A-0,590,629.

In addition to endless filaments (spunbond method) the textile surfacecan also be constructed of staple fibers or mixtures of staple fibersand endless filaments. The individual titers of the staple fibers in thenon-woven fabric are between 1 and 16 dtex, preferably 2 to 10 dtex. Thestaple length is 1 to 100 mm, preferably 2 to 500 mm, especiallypreferably 2 to 30 mm. The textile surface structure can also beconstructed of fibers of different materials in order to be able toachieve special properties.

The textile structure can also additionally have a reinforcement offibers, threads or filaments. Multi-filaments or rovings based on glass,polyester, carbon or metal are preferred as reinforcement threads. Thereinforcement threads can be used as such or also in the form of atextile surface structure, e.g., as fabric, laying, knitted fabric,knitwear or non-woven fabric. The reinforcements preferably consist of aparallel thread sheet or a laying.

The filaments and/or staple fibers constructing the bonded fiber fabriccan have a practically round cross-section or also other forms such asdumbbell-shaped, kidney-shaped, triangular or tri- or multi-lobedcross-sections. Hollow fibers and bi- or multi-component fibers can alsobe used. Furthermore, the melded fibers can also be used in the form ofbi-component or multi-component fibers.

The fibers forming the textile structure can be modified by customaryadditives, e.g., by antistatic agents such as carbon black.

The weight per unit area of the textile structure of fibers of syntheticpolymers is between 10 and 500 g/m², preferably 20 and 250 g/m², whereinthe data refers to a surface structure without any binders, additives orcoatings

Natural Fibers

The natural fibers are vegetable fibers, fibers derived from grasses,straw, wood, bamboo, reed and bast, or fibers of animal origin. Plantfibers is a collective concept and stands for seed fibers such ascotton, kapok or poplar fluff, bast fibers such as bamboo fiber, hemp,jute, linen or ramie, hart fibers such as sisal or manila, or fruitfibers such as coconut. Fibers of animal origin are wools, animal hairs,feathers and silks.

The weight per unit area of the textile structure of natural fibers isbetween 20 and 500 g/m², preferably 40 and 250 g/m², wherein the datarefers to a surface structure without any binders, additives or coatings

Natural Polymer Fibers

The textile surfaces of fibers of natural polymers are cellulose fibersuch as viscose or vegetable or animal protein fibers.

Among the textile surfaces of cellulose fibers non-woven fabrics areespecially preferred. They are constructed from filaments, that is,infinitely long fibers and/or from staple fibers. The average length ofthe staple fibers is between 1 and 25 mm, preferably 2 to 5 mm.

The average diameter of the cellulose fibers is between 5 and 50 μm,preferably between 15 and 30 μm.

The textile surface structure can also be Kraft papers, overlay papers,balance papers or decor papers. Such papers are particularly beneficialwhen used as core papers and/or as surface paper in CPL and HPL.

Binder Application

The new binder composition according to the present invention can beapplied to the textile structure after the textile structure has beenformed (off-line process). The new binder composition according to thepresent invention can also be applied during the manufacturing of thetextile structure (in-line process). Depending on the process chosen asuitable method for the binder application must be selected.

The application of the new binder composition according to the presentinvention onto the textile structure can take place with the aid of allknown methods. In addition to spraying on, impregnating and pressing in,the binder can also be applied by coating or by rotary nozzle heads. Iffollowing the inline process path the B-stage binder compositionaccording to the present invention can also be part of the white wateror any other aqueous means used for the production of the textilestructure.

A further preferred method is the application of the new bindercomposition according to the present invention by the application offoam. In the application of foam binder foam is produced with the aid ofa foaming agent in a foam mixer that is applied by suitable coatingaggregates onto the non-woven fabric. The application can also takeplace here by rotary nozzle heads.

In the foam coating of a B-stage-capable binder composition there arebasically no limitations regarding the foaming agent. Preferred foamingagents are ammonium stearates or succinic acid esters added with 1%-5%by weight in dry mass to the binder. Furthermore, the already describedcatalysts are mixed in if required. The solids content of the foam is atleast 40%, preferably at least 50%.

The total binder content in the textile surface structure is between 10%and 80% based on total weight of the dried surface structure andincludes all applied binder components and additives.

Functional Materials

The textile structure or the semi-finished textile structures comprisingthe new binder composition can contain additives and/or functionalmaterials. The additives and functional material can be applied at thesame time with the new binder composition, e.g., as mixture or asindividual components, or before or after the application of the bindercomposition. In as far as the new B-stage binder composition is appliedby foam application it is advantageous to apply the functional materialwith the foam or distributed in the foam or to apply the functionalmaterial onto the still fresh foam.

In order to fix the functional materials a binder can be additionallyadded for fixing the functional materials on the textile structure. Thesame binder composition is preferably selected here as is present in thetextile surface structure. The content of functional material isdetermined by the subsequent use.

The application of the functional material used takes place as afunction of the nature of the particular functional material by knowntechniques. The application can also take place by rotary nozzle heads.

The functional material is preferably flame proofing agents, materialsfor discharging electrostatic charges, materials for screening offelectromagnetic rays, organic or inorganic pigments, especially coloredpigments, materials that increase the resistance to wear and/orslippage, or decorative layers. The functional materials are preferablyarranged on the side of the textile surface structure and can at leastpartially pass through the non-woven fabric.

In a variant of the method an additional binder is added to fix thefunctional materials on the textile surface structure. The same binder(B-stage binder) as is present in the textile surface structure ispreferably selected here. The content of functional materials isdetermined by the subsequent use.

Flame Proofing Agents

The flame proofing agents are inorganic flame proofing agents,organophosphorus flame proofing agents, nitrogen-based flame proofingagents or intumescences flame proofing agents. Halogenated (brominatedand chlorinated) flame proofing agents can also be used but are lesspreferred on account of their risk evaluation. Examples for suchhalogenated flame proofing agents are polybrominated diphenylether,e.g., decaBDE, tetrabromobisphenol A and HBCD (hexabromocyclododecane).

The nitrogen-based flame proofing agents are melamines and urea.

The organophosphorus flame proofing agents are typically aromatic andalkyl esters of phosphoric acid. TCEP (trischloroethylphosphate), TCCP(trischloropropylphosphate), TDCCP (trisdichloroisopropylphosphate),triphenylphosphate, trioctylphosphate (tris-(2-ethylhexyl) phosphate)are preferably used.

The inorganic flame proofing agents are typically hydroxides such asaluminum hydroxide and magnesium hydroxide, borates such as zinc borate,ammonium compounds such as ammonium sulfate, red phosphorus, antimonyoxides such as antimony trioxide and antimony pentoxide and/or laminatedsilicates such as vermiculite. In addition, preferred agents areexpandable graphite.

Antistatic Agents

Antistatic- and electromagnetic screening effects can be achieved by theuse of agents for raising the electrical conductivity.

The antistatic agents are usually particles that are electricallyconductive. Suitable materials are electrically conductive carbons suchas carbon black, graphite and carbon nanotubes (C-nanotubes), conductiveplastics or fibers of metal or metallic components.

Electrically Conductive Materials

The materials for screening electromagnetic rays are usuallyelectrically conductive materials. They can be built up in the form offoils, particles, fibers or wires and/or textiles surface structures ofthe previously cited materials.

Fillers

Fillers are materials such as CaCO₃, coated CaCO₃, coated or uncoatedKaolin, talcum, gypsum or silica, etc.

Pigments

The inorganic or organic pigments are particulate materials. In additionto fillers such as CaCO₃, talcum, gypsum or silica, the pigments, to theextent that they should increase the value of the composite material,are in particular pigments that can be used in colors.

Hydrophobic Agents

Hydrophobic agents are additives which are able to increase or modifythe compatibility of the B-stage binder composition to the carrier orthe textile structure. Prominent but not limiting examples are fluorineor silane containing components which can greatly improve thecompatibility of the binder to metal and glass surfaces.

Surface Coatings

In addition to increasing the value, materials are also used thatincrease the application suitability. In particular an anti-slippagecoating is to be understood here as well as a coating that ensures anincreased wear protection. SiC and/or SiO₂ particles are preferably usedfor the anti-slippage coating with a grain size of preferably 2-5 mm.The amount is 1-40%, preferably 10-30% by weight based on the totalweight of the textile structure. In order to increase the effectivenessof the coating and to reduce the amount of the coating used the surfacecan additionally be structured.

Comparable materials are used for the surface enhancement in order toimprove the abrasion and hardness. However, grain sizes of below 1 mmare used, which can produce a very hard surface.

In as far as the functional layer should be an anti-slippage coating, itis advantageous if it or the basic particles are present entirely or atleast partially worked into the textile surface structure and/or theB-stage binder composition. In particular in the case of ananti-slippage coating and service enhancement in order to improve theabrasion and hardness it is advantageous if the particles are applied onto the textile surface structure in such a manner that the particlesproject at least partially from the surface of the textile surfacestructure. The resulting rigidity, in particular for an anti-slippagecoating, must meet the appropriate national norms and regulations.

Decorative Elements

The decorative layers are decorative elements. This is understood toinclude decorative layers and patterns that increase the value of thecomposite material. Examples of such patterns are veneers, cork,decorative papers, foils with wood graining, overlay papers, HPL, CPL(laminates built up in multilayers) or chips of paper or plastic withdifferent colors that are also designated as decorative semifinishedproducts. For their part, these decorative semifinished products cancontain B-stage-capable binders and/or one or more textile surfaces,preferably non-woven or non-woven fabric layers.

Method of Manufacturing the Semi-Finished Textile Structure

Subject matter of the present invention is a method for the manufactureof a semi-finished textile structure comprising the measures:

-   a) Supplying of a textile structure, whereas the textile structure    optionally has received a pre-strengthening,-   b) Application of at least one binder composition comprising (i) at    least one B-stage binder and (ii) at least one emulsion, preferably    a thermoplastic emulsion, in particular the emulsion is being based    on polyolefin and/or polyurethane,-   c) Optionally applying at least one functional material to the    textile structure according to b),-   d) Drying the textile structure so that the B-stage binder is at    least partially cured and being in the B-stage state.

The textile structure in measure a) has preferred an additionalpre-strengthening treatment as already described above. However, it isalso possible to apply the binder composition according to the presentinvention to the textile structure during its formation. In thisso-called in-line process measures a) and b) step are carried outsimultaneously at the same time during the formation of the textilestructure. The inline process does not necessarily requirepre-strengthening means if the B-stage binder composition itself canprovide sufficient binding strength.

The application of the binder in step b) can be accomplished asdescribed above. Optionally, functional materials can be applied. Thefunctional materials can be applied together with the binder or afterthe application of the binder. The subsequent drying step removes thewater and partially cures the B-stage binder to a B-stage condition.

The temperature and duration of the drying step depends on the materialsused, the process, and the planned applications. It is particularlyimportant to set the temperature and drying duration according to therequired degree of curing of the B-stage binder composition. In general,the drying parameters to be chosen are similar to those for theprocessing of B-stage papers, overlay papers, or decor papers.

The process results in a semi-finished product, comprising a textilestructure, a B-stage binder composition according to the presentinvention in a B-Stage state, and optionally functional materials. Thesemi-finished product can be used for the manufacturing of laminates ofall kind, in particular as reinforcement in laminates or as componentsof CPL or HPL.

Semi Finished Product

Further subject matter of the present invention is thus a semi-finishedproduct comprising at least one textile structure comprising at leastone binder composition comprising (i) at least one B-stage binder and(ii) at least one emulsion, preferably a thermoplastic emulsion, inparticular the emulsion is being based on polyolefin and/orpolyurethane, which is at least partially cured and being in the B-stagestate, and wherein the textile structure has optionally an additionalstrengthening, and optionally functional materials.

Thus, subject matter of the present invention is a semi-finished productcomprising

-   a) at least one textile structure, and-   b) at least one binder composition comprising (i) at least one    B-stage binder and (ii) at least one emulsion, preferably a    thermoplastic emulsion, in particular the emulsion is being based on    polyolefin and/or polyurethane, which is at least partially cured    and being in the B-stage state, and wherein the textile structure    has optionally an additional strengthening,-   c) Optionally functional materials.

The additional strengthening of the textile surface structure hasalready been described above. The same applies to the optionally appliedfunctional materials. When using the inline process the additionalstrengthening can be small or even not existing. The textile structureis preferably a nonwoven, woven, or paper, as explained earlier. Papersare preferably overlay papers or decor papers.

Decorative Semi-Finished Product

Furthermore, the invention also comprises decorative semifinishedproducts, in particular CPL and HPL, comprising:

-   a) at least one textile structure, preferably a non-woven fabric,    and-   b) at least one binder composition comprising (i) at least one    B-stage binder and (ii) at least one emulsion, preferably a    thermoplastic emulsion, in particular the emulsion is being based on    polyolefin and/or polyurethane, which is at least partially cured    and being in the B-stage state, and wherein the textile structure    has optionally an additional strengthening, and-   c) at least one decorative layer, preferably a layer or pattern of    veneers, cork, decorative papers, foils with wood graining, overlay    papers, HPL, CPL (laminates built up in multilayers) or chips of    paper or plastic with different colors.

CPL and HPL typically consist of several, usually 2-50 layers of Kraftpaper that are impregnated with a melamine, MUF or phenol B-stagebinder. In as far as these CPLs and/or HPLs comprise at least onenon-woven fabric containing B-stage binder composition in the B-Stage, asignificant reduction of the number of layers of Kraft paper up to acomplete replacement of the paper layers can take place.

The use of a non-woven fabric comprising a B-stage binder composition inthe B-stage reduces the number of layers of Kraft paper by at least onelayer, but preferably by at least 50% of the layers of Kraft paper withotherwise identical properties of the laminate. The reduction of theamount of binder-impregnated Kraft paper allows an improvement of thefire classification, which can extend to the classification of“noncombustible”.

The CPLs and/or HPLs in accordance with the invention preferably havebetween 1 and 25 layers of a non-woven fabric with a B-stage binder. Inaddition, the CPLs and/or HPLs in accordance with the invention can haveeven more layers of Kraft paper impregnated with amelamine-formaldehyde, melamine-urea-formaldehyde or phenol-formaldehygeresin.

As mentioned above the textile structure of the semi-finished productswhich comprises the B-stage binder composition in B-stage conditions canalso be Kraft papers. Such CPLs or HPLs offer a greatly improvedmechanical flexibility compared to standard CPL or HPL. The textilestructures comprising the B-stage binder composition in B-Stageconditions can also be overlay papers, balance papers or decor papers.All such papers are particularly beneficial when used as core papersand/or surface paper in CPL and HPL. In this case, a reduction of layersmight not take place, but the resulting CPL or HPL shows improvedflexibility and post-forming characteristics, in particular3-dimensional forming capabilities. CPL or HPL can also comprise veneerlayers.

The manufacture of the decorative semifinished product takes place bylamination under the action of pressure and heat in such a manner thatthe binder present in the B stage is partially or finally hardened. Thelamination can takes place by discontinuous or continuous pressing or byrolling. The parameters of pressure, temperature and dwell time areselected in accordance with the B-stage binder used.

The semi-finished products according to the present invention exhibit asignificant increase in flexibility and mechanical bending capabilities.The improved flexibility and mechanical bending capabilities can bemeasured as impact behavior in accordance with DIN EN 14323, DIN EN13329 and DIN EN 438 part 1 to part 6.

The flexibility can be measured using a Standard Werzalit analysatoravailable from Werzalit. The measurements are carried out under standardconditions (160° C.).

The binder composition according to the instant invention provides avery good flexibility of the textile structure when applied. Theflexibility provided is at least 20%, preferably at least 25%, inparticular at least 30%, most preferred 35% when applied to a glassfiber nonwoven having an area weight of 160 grams/square meter(StabilStrand□□EW160 C nonwoven available from Johns Manville SalesGmbH, Bobingen, Germany); 105 g/m² of B-Stage binder(melamine-formaldehyde B-Stage binder) with 1% thermoplastic emulsion(polyolefin, polypropylene DSM Nx777).

State of the art products are often brittle making the handlingdifficult and troublesome. The new product minimizes these problems. Inaddition, the generation of dust that almost always occurs duringmanufacturing and during the subsequent process steps can be greatlyreduced or even totally suppressed. When using the inventivesemi-finished products for the manufacture of laminates these laminatesexhibit a superior mechanical flexibility and bending behavior comparedto standard products.

The new B-stage binder composition in the textile structure stronglyimproves the compatibility to additives and functional materialsallowing the use of a broader range of materials. In addition, the newB-stage binder composition increases the compatibility to the carriermaterials, such as to WPC (wood plastic composites), plastics andmetals.

Laminates and Composites

Subject matter of the present invention are also laminates andcomposites comprising at least one textile structure utilizing the newbinder composition comprising (i) at least one B-stage binder and (ii)at least one emulsion, preferably a thermoplastic emulsion, inparticular the emulsion is being based on polyolefin and/orpolyurethane, and the method for the manufacture of suchlaminates/composites.

As mentioned above the textile structures are preferably nonwoven, wovenfabrics, or papers.

Laminates consists of several layers of different materials and/orstructures which are laminated under the action of pressure and heat.When using textile structures comprising binder in B-stage the binderreceives its final hardening.

Composites and laminates are well known in the art. Composites andlaminates have been utilized in many application fields because thepossibility to use different materials and layer structures offers alarge variety of different product properties.

Method of Manufacturing Composites

Subject matter of the present invention is a method for the manufactureof a composite material comprising the measures:

-   a) Supplying of a carrier,-   b) Application of a textile structure onto at least one surface of    the carrier, the textile structure having at least one binder    composition comprising (i) at least one B-stage binder and (ii) at    least one emulsion, preferably a thermoplastic emulsion, in    particular the emulsion is being based on polyolefin and/or    polyurethane, which is at least partially cured and being in the    B-stage state, and wherein the textile structure has optionally an    additional strengthening, and optionally at least one functional    material,-   c) Lamination of the construction obtained according to step b)    under the action of pressure and heat so that the binder present in    the B stage receives its final hardening,-   d) Optional application of at least one further protective layer and    drying.

The carrier used in accordance with step a) is preferably woodenmaterials like engineered wood, papers, cork, cardboards, mineralplates, wood-plastic-composites and/or so-called honeycombs. Honeycombsare structural components with three-dimensional reinforcementstructures that make possible an extraordinary stability and strengthwith low weight at the same time on account of their construction (beehoneycomb structure). Such honeycombs have been used for some time inmany areas of application, among others also as inner reinforcement ofplate-shaped elements in the construction area or in furniture.

Wooden Carrier

The wooden materials are plate-shaped or strand-shaped wooden materialsmanufactured by mixing the different wooden particle forms with naturaland/or synthetic binding agents during a hot pressing. The woodenmaterials used in accordance with the invention preferably compriseplywood or laminated wood, wood-chip material, especially chipboards andOSB (Oriented Strand Boards), wood fiber material, especially porouswood fiber boards, open-diffusion wood fiber boards, hard (high-density)wood fiber boards (HDF) and medium-density wood fiber boards (MDF), andArboform. Arboform is a thermoplastically workable material of ligninand other wood components.

Papers and Cardboards

The papers are preferably papers on the basis of natural, synthetic,mineral or ceramic fibers or also of mixtures of these fiber types.

The cardboards are preferably cardboards on the basis of natural and/orsynthetic fibers, which also comprise mineral and/or ceramic fibers aswell as mixtures of these fiber types.

Mineral Plates

The mineral plates are preferably commercial mineral cardboard plateswith cardboard coating on both sides, gypsum fiber plates, ceramic fiberplates, cement plates or lime plates. The plates can optionally bereinforced with natural and/or synthetic fibers, wherein these can alsocomprise mineral and/or ceramic fibers. The reinforcement fibers can bepresent in the form of filaments, monofilaments or as staple fibers.

In addition to the described materials the carrier can also consist ofcork, veneer or other sustainable vegetable materials.

The carrier can also be a WPC (wood-plastic-composite), a foam or otherplastic sheet materials. In the case of foam, the material needs to haveenough strength to withstand the pressure during the laminating process.

The weight per unit area of the carriers contained in the compositematerial is a function of the final application and is not subject toany particular limitation.

The lamination of the construction obtained according to step b) takesplace in step c) under the action of pressure and heat in such a mannerthat the binder present in the B stage receives its final hardening. Thelamination can take place by discontinuous or continuous pressing or byrolling. The parameters of pressure, temperature and dwell time areselected in accordance with the B-stage binder used.

The application of at least one further protective layer and its dryingin accordance with step d) takes place by known pressure, spraying andlacquering technologies. The application can also take place here byrotary nozzle heads. The drying of the protective layer takes place as afunction of the selected system.

The protective layers are usually lacquers such as powdered lacquers,clear lacquers or transparent lacquers, preferably scratch-prooflacquers that protect the functional layer against mechanical influencesor against UV ageing.

Method of Manufacturing Composites (Variant)

In a variant of the method in accordance with the invention in measureb) the textile structure can be applied with only at least one B-stagebinder composition in the B-Stage state and the providing with at leastone functional material can take place in a step after measure b). Sucha method—also comprised by the present invention—comprises the measures:

-   I) Supplying of a carrier,-   II) Application of the textile structure on at least one surface of    the carrier, the textile structure having at least one binder    composition comprising (i) at least one B-stage binder and (ii) at    least one emulsion, preferably a thermoplastic emulsion, in    particular the emulsion is being based on polyolefin and/or    polyurethane, which is at least partially cured and being in the    B-stage state, and wherein the textile structure has optionally an    additional strengthening,-   III) Optional lamination of the construction obtained according to    step II) under the action of pressure and heat so that the binder    present in the B stage partially or completely hardens,-   IV) Application of at least one functional material on the side of    the textile structure facing away from the carrier,-   V) lamination of the construction obtained according to step IV)    under the action of pressure and heat so that the binder present in    the B stage receives its final hardening,-   VI) Optional application of at least one further protective layer    and drying.

The measures I), V) and VI) are identical with the initially citedmeasures a), c) and d).

The application of the textile structure containing at least one binderin the B-stage state takes place according to step II) as initiallydescribed under measure b), wherein the functional material is notpresent.

The lamination according to measure III) and VI) takes place under theaction of pressure and heat in such a manner that the binder present inthe B stage receives its partial higher or final hardening. Thelamination can take place by discontinuous or continuous pressing or byrolling. The parameters of pressure, temperature and dwell time areselected in accordance with the B-stage binder used.

Composite Material

In addition to the above-described methods, further subject matter ofthe present invention is a composite material comprising:

-   a) A carrier,-   b) At least one textile structure applied onto at least one of the    two sides of the carrier which textile structure comprises at least    one finally hardened B-stage binder composition obtained from a    binder composition comprising (i) at least one B-stage binder    and (ii) at least one thermoplastic emulsion, preferably the    emulsion being based on polyolefin and/or polyurethane, said textile    structure optionally being additionally strengthened, and-   c) Optionally at least one functional material applied on the top of    the textile structure provided with the B-stage binder composition    or introduced into the textile structure comprising the binder    composition,-   d) Optionally further protective layers applied on the functional    material.

Variations and modifications of the method in accordance with theinvention are possible by using selected textile structures. Textilestructures are preferably nonwoven, woven fabrics, or papers.

The textile structures which comprise the at least one finally hardenedB-stage binder composition can have an additional strengthening asdescribed above. In particular when following the offline process routethe textile structures comprise an additional strengthening. Theadditional strengthening of the textile structure has already beendescribed above. The same applies to the carrier, the B-stage binder,the functional material and the protective layers.

Composite Material with CPL/HPL as Functional Material

Furthermore, the invention also comprises a composite material in whichthe functional material applied is a decorative product, in particularCPL and HPL.

In addition to the above-described methods, further subject matter ofthe present invention is a composite material comprising:

-   a) A carrier,-   b) At least one textile structure applied onto at least one of the    two sides of the carrier which textile structure comprises at least    one finally hardened B-stage binder composition obtained from a    binder composition comprising (i) at least one B-stage binder    and (ii) at least one thermoplastic emulsion, preferably the    emulsion being based on polyolefin and/or polyurethane, said textile    structure optionally being additionally strengthened, and-   c) at least one functional material applied on the top of the    textile structure provided with the B-stage binder composition or    introduced into the textile structure comprising the binder    composition, said functional material being at least one decorative    layer, preferably a layer or pattern of veneers, cork, decorative    papers, foils with wood graining, overlay papers, HPL, CPL    (laminates built up in multilayers) or chips of paper or plastic    with different colors,-   d) Optionally further protective layers applied on the functional    material.

Variations and modifications of the method in accordance with theinvention are possible by using selected textile structures. Textilestructures are preferably nonwoven, woven fabrics, or papers.

The textile structures which comprise the at least one finally hardenedB-stage binder composition can have an additional strengthening asdescribed above. In particular when following the offline process routethe textile structures comprise an additional strengthening. Theadditional strengthening of the textile structure has already beendescribed above. The same applies to the carrier, the B-stage binder,the functional material and the protective layers.

The manufacture of the decorative finished product takes place bylamination under the action of pressure and heat in such a manner thatthe binder present in the B stage is finally hardened. The laminationcan takes place by discontinuous or continuous pressing or by rolling.The parameters of pressure, temperature and dwell time are selected inaccordance with the B-stage binder used.

CPL/HPL Decorative Laminates

As mentioned above the manufacture of the decorative semifinishedproduct takes place by lamination under the action of pressure and heatin such a manner that the binder present in the B stage is partially orfinally hardened. The lamination can takes place by discontinuous orcontinuous pressing or by rolling.

Therefore, finally hardened decorative multilayer products, such likeHPL or CPL, comprising at least one textile structure which comprises atleast one finally hardened B-stage binder composition obtained from abinder composition comprising (i) at least one B-stage binder and (ii)at least one thermoplastic emulsion, preferably the emulsion being basedon polyolefin and/or polyurethane, are also subject matter of thepresent invention.

The parameters of pressure, temperature and dwell time are selected inaccordance with the B-stage binder used.

The manufacture of the decorative finished product takes place bylamination under the action of pressure and heat in such a manner thatthe binder present in the B stage is finally hardened. The laminationcan takes place by discontinuous or continuous pressing or by rolling.The parameters of pressure, temperature and dwell time are selected inaccordance with the B-stage binder used.

The finished products including the decorative finished products whichcomprises the finally hardened B-stage binder composition exhibitimproved post-forming capabilities, in particular if used for narrowradii or edges.

CPL/HPL Decorative Composites

Composite materials comprising HPL or CPL comprising at least onetextile structure which comprises at least one finally hardened B-stagebinder composition are also subject matter of the invention.

Therefore, in addition to the above-described composite material,further subject matter of the present invention is a laminatecomprising:

-   a) A carrier,-   b) At least one CPL or HPL layer applied onto at least one of the    two sides of the carrier which CPL or HPL comprises at least one    textile structure comprising at least one finally hardened B-stage    binder composition obtained from a binder composition comprising (i)    at least one B-stage binder and (ii) at least one thermoplastic    emulsion, preferably the emulsion being based on polyolefin and/or    polyurethane, said textile structure optionally being additionally    strengthened, and-   c) Optionally further protective layers applied on the functional    material.

The carrier and the CPL or HPL layer are laminated by using standardglues or binding means compatible to the materials used. The laminationprocess and its parameters are selected in accordance with the materialsused.

As explained before, CPL and HPL typically consist of several, usually2-50 layers of Kraft paper that are impregnated with amelamine-formaldehyde, melamine-urea-formaldehyde, orphenol-formaldehyde resind. In as far as these CPLs and/or HPLs compriseat least one non-woven fabric containing B-stage binder composition, asignificant reduction of the number of layers of Kraft paper up to acomplete replacement of the paper layers can take place.

The use of a non-woven fabric comprising a B-stage binder compositionreduces the number of layers of Kraft paper by at least one layer, butpreferably by at least 50% of the layers of Kraft paper with otherwiseidentical or improved properties of the laminate. The reduction of theamount of binder-impregnated Kraft paper allows an improvement of thefire classification, which can extend to the classification of“noncombustible”.

As mentioned above the textile structures of the decorative finishedproducts which comprises the finally hardened B-stage binder compositioncan also be Kraft papers. Such CPLs or HPLs offer a greatly improvedmechanical flexibility compared to standard CPL or HPL based on standardresin compositions. The textile structures comprising the B-stage bindercomposition can also be overlay papers, balance papers or decor papers.All such papers are particularly beneficial when used as core papersand/or surface paper in CPL and HPL (no reduction of layers in case ofpaper).

The previously cited materials are suitable as carrier, textilestructure, B-stage binder, functional material and protective layer. Thepreferred embodiments disclosed in the scope of the method in accordancewith the invention also apply to the composite material of theinvention.

The previously cited functional material can be present in the form ofan independent layer applied in the B-stage on the side of the textilestructure facing away from the carrier or can also entirely or partiallypenetrate the textile structure. These embodiments are suitable forfunctional materials such as flame proofing agents, materials fordischarging electrostatic charges, materials for screening offelectromagnetic charges, materials for screening off electromagneticrays, organic or inorganic pigments, especially colored pigments ordecorative layers.

In a preferred embodiment the functional material forms a discrete layerin the composite material of the invention. This embodiment isespecially suitable for functional materials that increase theresistance to wear and/or slippage and/or increase the value by theoptical effect of the surface. It is especially advantageous if thefunctional material is to make anti-slippage material or an increasedresistance to wear if the basic particles project at least partiallyfrom the textile structure provided with the B-stage binder.

The functional material is present in the carrier and/or on the side ofthe textile structure facing away from the carrier.

The composite material in accordance with the invention makes possible adirect workability for the subsequent applications since the compositematerial already contains the necessary provisioning with functionalmaterial.

The inventive laminates and composites exhibit a superior mechanicalflexibility and bending behavior compared to standard products. Inaddition the impact resistance is greatly increased making these newproducts extremely suitable for mechanically challenging environments.

The strongly increased mechanical performance of the inventive compositematerials, in particular composites comprising wooden material such asengineered wood, offer additional advantages. Due to the uniquecombination of flexibility and mechanical strength of the novel bindercontaining textile structures certain mechanical treatments likenailing, screwing, drilling or any other application of punctual forceare possible without damaging the composite or surface layers. Typicallycracks, bursts, and other damages occur if composites comprisingdifferent materials are treated with nails etc. The inventive binderavoids these kind of problems offering great advantages for thefurniture industry and construction industry, e.g when used in concreteforms.

As already mentioned above due to the addition of thermoplasticemulsions, the compatibility and therefore the mechanical properties ofthe final composites can be improved. The emulsion can act as a couplingagent between a carrier with non-compatible characteristics to theB-stage binder and the laminated layer.

In decorative laminates it is quite common to add 3-dimensionalstructures to the laminate using e.g. a structured press plates. Thiskind of treatment usually reduces the impact performance. The inventivebinder composition allows an improved impact performance also for suchstructured laminates.

EXAMPLES Example 1

A laminate was produced comprising a balance paper, a particle board, aglass fiber nonwoven layer, a decor paper, and an overlay paper. Thebalance paper was a standard type with 140 g/m² specific weight. Theparticle board was a standard particle board according to P2 norm with adensity of 650 kg/m³ and thickness of 17 mm. The glass fiber nonwovenwas a StabilStrand□□EW160 C nonwoven produced by Johns Manville SalesGmbH, Bobingen, Germany.

This nonwoven comprises 105 g/m² of a melamine-formaldehyde B-Stagebinder. The decor paper is a standard furniture paper of 50 g/m² weightcomprising 160 g/m² of a melamine-formaldehyde B-stage binder.

The overlay paper is a standard AC3 paper with 22 g/m² weight and 78g/m² standard binder.

The laminate was manufactures on a short-cycle-press laminated at 200°C. and 25 bar for 25 sec.

The impact behavior was measured according to DIN EN14323, DIN EN 13329,and DIN EN438 part 1-6. The results are listed in table 1.

Example 2

A laminate was produced with the same structure and under the sameconditions like in Example 1. However, the overlay paper comprises theinventive binder composition. The binder composition was amelamine-formaldehyde binder modified with 1% PP emulsion DSM Nx777. Theresults are listed in table 1.

Examples 3-7

Glass fiber nonwoven samples were produced based on StabilStrand□□EW160C nonwoven produced by Johns Manville Sales GmbH, Bobingen, Germany. 105g/m² of a melamine-formaldehyde B-stage binder compositions were addedto the samples with different emulsion contents.

Example 3 was made with a melamine-formaldehyde B-stage binder withoutany emulsion modifications. The data and results are listed in table 2.

The flexibility of the nonwoven was determined by using a Werzalitanalysator which is well known and widely used in the field. This methodallows the determination of the sample flexibility by measuring thedynamic cure and flow times of the resins in the sample.

TABLE 1 (impact testing) Sample Force (small ball) Distance (large ball)Example 1 13N  50 cm Example 2 16N 150 cm

TABLE 2 (flexibility testing) Sample Cure time (mm) flow (sec)Flexibility (%) Example 3 0.2 10 16 1% PP (DSM Nx777) 0.3 12 36 2% PP(DSM Nx777) 0.4 14 46 5% PP (DSM Nx777) 0.6 19 50 5% PP (AC Priex 703)0.5 17 39

1. A semi-finished product comprising: a textile structure; and abinder, wherein the binder is made from a binder composition comprising:a B-stage binder composition, and an emulsion, wherein the semi-finishedproduct can undergo further hardening of the binder.
 2. Thesemi-finished product of claim 1, wherein the textile structurecomprises at least one type of fiber selected from the group consistingof natural fibers, fibers of synthesized polymers, fibers of naturalpolymers, ceramic fibers, mineral fibers, and glass fibers.
 3. Thesemi-finished product of claim 1, wherein the textile structurecomprises at least one material selected from the group consisting of atissue, laying, multiaxial fabric, knitted fabric, woven fabric,non-woven fabric, and paper.
 4. The semi-finished product of claim 1,wherein the B-stage binder composition comprises a thermoset bindercomposition.
 5. The semi-finished product of claim 1, wherein theB-stage binder composition comprises a formaldehyde-free bindercomposition.
 6. The semi-finished product of claim 1, wherein theB-stage binder composition comprises at least one binder compositionselected from the group consisting of furfuryl alcohol formaldehyde,phenol formaldehyde, melamine formaldehyde, and urea formaldehyde. 7.The semi-finished product of claim 1, wherein the emulsion comprises athermoplastic emulsion.
 8. The semi-finished product of claim 1, whereinthe emulsion comprises a polyolefin emulsion.
 9. The semi-finishedproduct of claim 1, wherein the polyolefin emulsion comprisespolypropylene.
 10. The semi-finished product of claim 1, wherein theemulsion is 0.1 wt. % to 35 wt. % based on a total solids content of thebinder composition.
 11. The semi-finished product of claim 1, whereinthe emulsion is not a thermoset emulsion that has three-dimensionalcrosslinking.
 12. The semi-finished product of claim 1, wherein thebinder composition further comprises a hardening catalyst for theB-stage binder composition.
 13. The semi-finished product of claim 12,wherein the hardening catalyst is selected from the group consisting ofammonium nitrate, p-toluene sulfonic acid, and maleic acid.
 14. Thesemi-finished binder product of claim 12, wherein the hardening catalystcomprises 0.25 wt. % to 7 wt. % relative to the total binder content.15. The semi-finished binder product of claim 1, wherein the binder is10 wt. % to 30 wt. % of a weight of the textile structure.
 16. Thesemi-finished binder product of claim 1, wherein the semi-finishedbinder product further comprises at least one functional materialselected from the group consisting of a flame proofing agent, a materialto discharge electrostatic charge, a material to screen offelectromagnetic rays, a filler, a pigment, a material to increaseresistance to wear, a material to increase resistance to slippage, and adecorative element.
 17. A semi-finished binder product comprising: atextile fabric; and a partially-cured binder, wherein thepartially-cured binder comprises a partially-polymerized thermosetpolymer and a thermoplastic polymer selected from polyolefins andpolyurethanes, and wherein the thermoplastic polymer does not havethree-dimensional crosslinking.
 18. The semi-finished binder product ofclaim 17, wherein the textile fabric comprises at least one type offiber selected from the group consisting of natural fibers, fibers ofsynthesized polymers, fibers of natural polymers, ceramic fibers,mineral fibers, and glass fibers.
 19. The semi-finished binder productof claim 18, wherein the textile fabric comprises glass fibers, andwherein the glass fibers comprise one or more types of glass selectedfrom the group consisting of A-glass, C-glass, E-glass, S-glass,T-glass, and R-glass.
 20. The semi-finished binder product of claim 18,wherein the textile fabric comprises fibers of synthesized polymers, andwherein the fibers of synthesized polymers comprise one or more types ofsynthesized polymers selected from the group consisting of polyamides,polyesters, polyethylene, polypropylene, and polybenzimidazoles.
 21. Thesemi-finished binder product of claim 17, wherein thepartially-polymerized thermoset polymer comprises a formaldehyde-freepolymer.
 22. The semi-finished binder product of claim 17, wherein thepartially-polymerized thermoset polymer is selected from the groupconsisting of furfuryl alcohol formaldehyde, phenol formaldehyde,melamine formaldehyde, and urea formaldehyde.
 23. The semi-finishedbinder product of claim 17, wherein the thermoplastic polymer comprisespolypropylene.
 24. The semi-finished binder product of claim 17, whereinthe partially-cured binder further comprises a hardening catalyst forthe partially-polymerized thermoset polymer, and wherein the hardeningcatalyst is selected from the group consisting of ammonium nitrate,p-toluene sulfonic acid, and maleic acid.
 25. The semi-finished binderproduct of claim 17, wherein the semi-finished binder product furthercomprises at least one functional material selected from the groupconsisting of a flame proofing agent, a material to dischargeelectrostatic charge, a material to screen off electromagnetic rays, afiller, a pigment, a material to increase resistance to wear, a materialto increase resistance to slippage, and a decorative element.
 26. Asemi-finished binder product comprising: a textile structure; and aB-stage binder, wherein the B-stage binder comprises a B-stage thermosetpolymer, and a polyolefin polymer derived from a polyolefin emulsionthat does not have three-dimensional crosslinking.
 27. The semi-finishedproduct of claim 26, wherein the textile structure comprises at leastone type of fiber selected from the group consisting of natural fibers,fibers of synthesized polymers, fibers of natural polymers, ceramicfibers, mineral fibers, and glass fibers.
 28. The semi-finished productof claim 26, wherein the B-stage thermoset polymer comprises aformaldehyde-free polymer.
 29. The semi-finished product of claim 26,wherein the B-stage thermoset polymer is selected from the groupconsisting of furfuryl alcohol formaldehyde, phenol formaldehyde,melamine formaldehyde, and urea formaldehyde.
 30. The semi-finishedproduct of claim 26, wherein the polyolefin polymer comprises apolypropylene polymer.